Apparatus and method for adjusting and controlling the stacking-up layer manufacturing

ABSTRACT

An apparatus of adjusting and controlling the stacking-up layer manufacturing comprises a target, a powder providing unit, an energy generating unit, and a magnetism unit. The powder providing unit is coupled on a top of the target. The energy generating unit is also coupled on the top of the target. The powder providing unit provides a powder to a surface of the target. The energy generating unit provides the energy beam to selectively heat the powder on the surface of the target to form a melted or sintered powder layer. The magnetism unit provides a magnetic field to control the solidification of the melted or sintered powder layer.

CROSS REFERENCE TO RELATED APPLICATION

The present application is based on, and claims priority from, Taiwan(International) Application Serial Number 102147539, filed on Dec. 20,2013, the disclosure of which is hereby incorporated by reference hereinin its entirety.

TECHNICAL FIELD

The present disclosure relates to an apparatus and a method foradjusting and controlling the stacking-up layer manufacturing, and moreparticularly to the apparatus and the method for adjusting andcontrolling the material microstructure of stacking-up layermanufacturing product.

BACKGROUND

Conventional manufacturing methods such as the casting can only provideproducts with fixed configurations. If there is a need for improvingmaterial properties (strength and surface hardness for example) of theproduct to meet various requirements, a further relevant heat treatmentcan be applied so as to form a homogeneous internal texture or toprovide a controllable surface. If the need is to modify theconfiguration of the object, then some specific manufacture methods canalso be available already in the art.

The stacking-up layer or additive manufacturing method is a method forproducing products with complicated configurations. Currently, amongvarious additive manufacturing methods, powder bed fusion and directenergy deposition are two major application types of the metal additivemanufacturing. The powder bed fusion of the additive manufacturingprocess comprises selective laser sintering (SLS), selective lasermelting (SLM), direct metal laser sintering (DMLS), electron beammelting (EBM), and other relative techniques of powder bed fusionforming method. The direct energy deposition of the additivemanufacturing process comprises laser engineering net shaping (LENS),laser metal deposition (LMD), 3D laser cladding, and other relativetechniques of direct energy deposition forming method.

In all the aforesaid additive manufacture methods, during thesolidification process, the phase change of the material between thesolid state and the liquid state and the crystallizing mechanism maygreatly be affected by the energy of the heating source (such as laseror electron beam) and the scanning speed. If provided energy isexcessive, material may be vaporized. On the other hand, if providedenergy is insufficient, the melting or sintering process isinsufficient. In addition, while the scanning speed of the energy beamsis too fast or too slow, quality of the additive manufacturing may bedegraded. Therefore, optimal process parameters for the current additivemanufacturing, or said as the stacking-up layer manufacturing, arelimited in a specific range, and the crystallization (such as thecrystal size and the crystal direction) of the material microstructureis usually uncontrollable by the variation of process parameters.

SUMMARY

The present disclosure is to provide an apparatus for adjusting andcontrolling the stacking-up layer manufacturing. The apparatuscomprises:

a target;

a powder providing unit, coupled on a top of the target, providing apowder to a surface of the target;

an energy generating unit, coupled also on the top of the target,providing an energy beam to selectively heat the powder on the surfaceof the target to form a melted or sintered powder layer; and

a magnetism unit, coupled also on the top of the target, providing amagnetic field to control solidification of the melted or sinteredpowder layer.

This disclosure further provides a method for adjusting and controllingthe stacking-up layer manufacturing. The method comprises the steps of:

providing a powder onto a surface of a target thereon;

directing an energy beam onto the powder on the surface of the target soas to melt or sinter a particular area of the powder to form a melted orsintered powder layer;

applying a magnetic field to the melted or sintered powder layer so asto control solidification of the melted or sintered powder layer andfurther to form a corresponding solidified layer; and

performing repeatedly the aforesaid three steps till a 3D product isformed by a sequence stacking with the solidified layers.

This disclosure further provides a control method for an apparatus foradjusting and controlling the stacking-up layer manufacturing, in whichthe apparatus for adjusting and controlling the stacking-up layermanufacturing comprises a target, a powder providing unit for providinga powder onto the target, an energy generating unit for providing anenergy beam and a magnetism unit for generating a magnetic field. Thecontrol method comprises the steps of:

providing the powder onto a surface of the target;

directing the energy beam onto the powder on the surface of the targetso as to melt or sinter a particular area to form a melted or sinteredpowder layer;

applying the magnetic field to the melted or sintered powder layer so asto control a solidification of the melted or sintered powder layer andfurther to form a corresponding solidified layer; and

performing repeatedly the aforesaid three steps till a 3D product isformed by a sequence stacking with the solidified layers.

Further scope of applicability of the present application will becomemore apparent from the detailed description given hereinafter. However,it should be understood that the detailed description and specificexamples, while indicating exemplary embodiments of the disclosure, aregiven by way of illustration only, since various changes andmodifications within the spirit and scope of the disclosure will becomeapparent to those skilled in the art from this detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become more fully understood from thedetailed description given herein below and the accompanying drawingswhich are given by way of illustration only, and thus are not limitativeof the present disclosure and wherein:

FIG. 1 is a schematic view of a first embodiment of the apparatus foradjusting and controlling the stacking-up layer manufacturing of thisdisclosure;

FIG. 2 is a schematic perspective view of FIG. 1;

FIG. 3 is a schematic enlarged view of the displacement unit 11, theadjustment module 12 and the magnetism unit 13 of FIG. 2;

FIG. 4 is a schematic exploded view of FIG. 3;

FIG. 5 is a schematic view of the magnetism unit 13 of the firstembodiment of this disclosure;

FIG. 6 is a schematic view of a second embodiment of the apparatus foradjusting and controlling the stacking-up layer manufacturing of thisdisclosure;

FIG. 7 is a schematic view of a third embodiment of the apparatus foradjusting and controlling the stacking-up layer manufacturing of thisdisclosure;

FIG. 8 is a schematic perspective of a fourth embodiment of theapparatus for adjusting and controlling the stacking-up layermanufacturing of this disclosure;

FIG. 9 is a schematic view of an embodiment of the magnetism unit ofthis disclosure;

FIG. 10 is a schematic view of a further embodiment of the magnetismunit of this disclosure;

FIG. 11 is a schematic view of a further embodiment of the magnetismunit of this disclosure;

FIG. 12 is a schematic view of a further embodiment of the magnetismunit of this disclosure;

FIG. 13 is a flowchart of an embodiment of the method for adjusting andcontrolling the stacking-up layer manufacturing of this disclosure;

FIG. 14 is a diagram showing the relationship between the crystal sizeand the magnetic field; and

FIG. 15 is another illustration of FIG. 14, in which curve C is acombination of curves A and B of FIG. 14.

DETAILED DESCRIPTION

In the following detailed description, for purposes of explanation,numerous specific details are set forth in order to provide a thoroughunderstanding of the disclosed embodiments. It will be apparent,however, that one or more embodiments may be practiced without thesespecific details. In other instances, well-known structures and devicesare schematically shown in order to simplify the drawing.

Referring now to FIG. 1 and FIG. 2, a schematic view and a correspondingperspective view of a first embodiment of the apparatus for adjustingand controlling the stacking-up layer manufacturing are shown,respectively. The first embodiment may comprise a powder providing unit10, a magnetism unit 13, an energy generating unit 14 and a target 15.

In this disclosure the target 15 may be a plate, a platform, asemi-finished product, or any the like. Also, the target 15 may bestationary or mobile.

The powder providing unit 10 may be coupled on a top of the target 15.The powder providing unit 10 may provide a powder 102 to the surface(top surface) of the target 15 by spraying, depositing, rolling,leveling, laying, or a combination of at least two of the foregoing. Inaddition, the powder providing unit 10 may be structured as one selectedfrom a group consisting of a knife-shape material providing module, ahopper material providing module, a spray material providing module, afeed-drum material providing module, and any the like. The foregoingmaterial providing modules may be utilized to control the laying,depositing, rolling, leveling, or spraying of the powder.

As shown in FIG. 2, the powder providing unit 10 may have a knife-shapematerial providing module 100 and a first Y-axis displacement module101. In this first embodiment, the knife-shape material providing module100 and the first Y-axis displacement module 101 demonstrate simply anexemplary example for the powder providing unit, and it is understoodthat the embodying of the powder providing unit 10 shall not be limitedto this pair of the knife-shape material providing module 100 and thesingle-axis displacement module 101. Anyway, in this embodiment, firstY-axis displacement module 101 may be coupled with the knife-shapematerial providing module 100 so as to allow the knife-shape materialproviding module 100 to perform a reciprocating motion along the Y axis.

Referring to FIG. 2, FIG. 3 and FIG. 4, the apparatus for adjusting andcontrolling the stacking-up layer manufacturing may further comprise adisplacement unit 11 that may comprise a second Y-axis displacementmodule 110, an X-axis displacement module 111 and a Z-axis displacementmodule 112.

The second Y-axis displacement module 110 may be coupled with theknife-shape material providing module 100, the X-axis displacementmodule 111 may be coupled with the second Y-axis displacement module110, and the Z-axis displacement module 112 may be coupled with theX-axis displacement module 111.

The apparatus for adjusting and controlling the stacking-up layermanufacturing may further comprise an adjustment module 12 that maycomprise a turning module 120, at least one protrusion module 121, atleast one angular adjustment modules 122 and at least one tilt modules123.

The turning module 120 may be coupled with the Z-axis displacementmodule 112. The protrusion module 121 may be coupled on top of theturning module 120. It may have two protrusion modules 121, and may belocated oppositely to each other. It may have two angular adjustmentmodules 122, and may be coupled on top of the respective protrusionmodule 121. It may have two tilt modules 123, and may be coupled top tothe respective angular adjustment module 122.

The magnetism unit 13 for generating a magnetic field 132 may have afirst magnetic pair 130, or a combination of the first magnetic pair 130and a second magnetic pair 131. In this embodiment, the magnetism unit13 may provide a magnetic field 132, as shown in FIG. 1. In otherembodiments, the magnetism unit 13 may alter the arrangement of thefirst magnetic pair 130 and the second magnetic pair 131, and mayprovide a static magnetic field, an alternative magnetic field or apulse magnetic field. Details for these would be elucidated in latersections.

The first magnetic pair 130 may be an electromagnetic member having twoelectromagnetic poles, or at least two electromagnetic members that eachof the at least two electromagnetic members may be coupled with therespective tilt module 123.

The second magnetic pair 131 may be an electromagnetic member having twoelectromagnetic poles, or at least two electromagnetic members forhelping to vary the strength of the first magnetic pair 130. Inaddition, the first magnetic pair 130 and the second magnetic pair 131may be coupled to the turning module 120. The first magnetic pair 130and the second magnetic pair 131 may be integrally arranged in asurrounding manner or any manner the like. In this embodiment, thesurrounding manner may be performed by a rectangular arrangement,referred to FIG. 5. The magnetic field 132 in this embodiment may belocated in the area surrounded by the first magnetic pair 130 and thesecond magnetic pair 131.

As mentioned above, the second Y-axis displacement module 110 may allowthe adjustment module 12 to perform reciprocating motion along the Yaxis. Similarly, the X-axis displacement module 111 may allow theadjustment module 12 to perform another reciprocating motion along the Xaxis, and the Z-axis displacement module 112 may allow the adjustmentmodule 12 to perform a respective reciprocating motion along the Z axis.

The turning module 120 may allow the magnetism unit 13 to rotate anangle about the Z axis.

The protrusion module 121 may adjust the spacing between the twoelectromagnetic poles of the first magnetic pair 130; i.e. to controlthe distance between the two electromagnetic members.

The angular adjustment module 122 may adjust the angling of the twoelectromagnetic poles of the first magnetic pair 130 with respect to theY axis.

The tilt module 123 may adjust the elevation angling of the twoelectromagnetic poles of the first magnetic pair 130 with respect to theZ axis.

Referred to FIG. 1, the energy generating unit 14, the adjustment module12, and the magnetism unit 13 may be coupled on top of the target 15 ineither a stationary or a mobile manner. The energy generating unit 14may generate an energy beam 140, in which the energy beam 140 may be alaser beam, an electron beam, an electric arc, or a combination of atleast two of the foregoing. The apparatus of this disclosure may beapplied to selective laser sintering (SLS), selective laser melting(SLM), direct metal laser sintering (DMLS), or electron beam melting(EBM).

Referring now to FIG. 6, a second embodiment of the apparatus foradjusting and controlling the stacking-up layer manufacturing of thisdisclosure is schematically shown. By comparing this second embodimentto the aforesaid first embodiment, the major difference is that thepowder providing unit 10A of the second embodiment may be selectivelydisconnected with the other elements, such as the displacement unit 11,the adjustment module 12, the magnetism unit 13, and the energygenerating unit 14.

In this second embodiment, the powder providing unit 10A may be movablycoupled on top of the target for providing a powder 102A onto thesurface of the target 15. The powder providing unit 10A here is embodiedagain as, but not limited to, a knife-shape material providing module.In addition, the powder providing unit 10A may be moved independently.This second embodiment of the apparatus of this disclosure can beapplied to selective laser sintering (SLS), selective laser melting(SLM), direct metal laser sintering (DMLS), or electron beam melting(EBM).

Referring now to FIG. 7, a third embodiment of the apparatus foradjusting and controlling the stacking-up layer manufacturing of thisdisclosure is schematically shown. By comparing this third embodiment tothe aforesaid first embodiment, the major difference in between is thatthe third embodiment has the energy generating unit 14B and the powderproviding unit 10B to replace the energy generating unit 14 and thepowder providing unit 10 of the first embodiment. Except for thischange, all other elements of these two embodiments such as thedisplacement unit 11, the adjustment module 12, the magnetism unit 13,and the target 15 are the same.

In this second embodiment, the powder providing unit 10B may be coupledwith the energy generating unit 14B to provide the powder 102B onto thetarget 15. The powder providing unit 10B may be a hopper materialproviding module or a spray material providing module. The energygenerating unit 14B may be movably coupled on top of the target 15, andmay direct an energy beam 140B onto the surface of the target 15 so asto selectively melt or sinter a predetermined area of the powder into amelted or sintered state.

The magnetism unit 13 may provide a magnetic field to the melted orsintered powder layer during the solidification process so as to controlthe material microstructures. The aforesaid magnetic field may be astatic magnetic field, an alternative magnetic field, or a pulsemagnetic field. The apparatus of this embodiment can be applied to aprocess of laser engineering net shaping (LENS), laser metal deposition(LMD), or 3D laser cladding.

Referring now to FIG. 8, a fourth embodiment of the apparatus foradjusting and controlling the stacking-up layer manufacturing of thisdisclosure is schematically shown in this embodiment, the apparatus maycomprise a station 60, a powder providing unit 61, a displacement unit62, a magnetism unit 63, and a target 64.

The target 64 located inside the station 60 may perform a verticalreciprocation motion. The displacement unit 62 is located on top of thetarget 64 inside the station 60. In this embodiment, the displacementunit 62 may replace the aforesaid first Y-axis displacement module 101and the displacement unit 11 of the first embodiment of FIG. 1, orsimply the first Y-axis displacement module 101 of FIG. 1.

The powder providing unit 61 may be coupled with the displacement unit62 to allow the powder providing unit 61 to perform a horizontalreciprocating motion with respect to the target 64. In this embodiment,the powder providing unit 61 further has a knife-shape powder providingunit, and the magnetism unit 63 coupled with the powder providing unit61 may also be located on top of the target 64.

In FIG. 8, though the aforesaid energy generating unit is notconfigured, yet it should be understood that lots of common elements orinterchangeable elements prevail among these embodiments of the presentdisclosure.

Referring now to FIG. 8, the powder providing unit 61 may provide apowder to the surface of the target 64 so as to form a layer of thepowder on the target 64.

The displacement unit 62 may move the powder providing unit 61. Inparticular, the displacement unit 62 may move the powder providing unit61 away from the target 64, and move the magnetism unit 63 to a topposition of the target 64; such that the magnetism unit 63 may moveaccordingly, via the displacement unit 62, with respect to the varyingof the focus position of the energy generating unit. In this embodiment,the magnetism unit 63 may be an electromagnetic member with two magneticpoles.

The energy generating unit may provide an energy beam to the powder onthe target surface. The magnetism unit 63 may provide a magnetic fieldto the powder on the target surface; such that the powder on the surfaceof the target may be heated by the energy beam and then be formed to amelted or sintered state. During a solidification process of the meltedor sintered powder layer, a mode, a direction, and a strength of themagnetic field are adjustable so as to control the materialmicrostructure of a solidified layer after the solidification process.

In this embodiment, the magnetic field may be a static magnetic field,an alternative magnetic field or a pulse magnetic field.

As long as the solidified layer is formed, the target 64 was lowered bya predetermined distance, then the powder providing unit is introducedagain to provide the powder to the target 64, and the same manufacturingsteps are performed again to form another solidified layer toping on theprevious one. According to this disclosure, the aforesaid steps offorming the solidified layer are performed repeatedly, till apredetermined 3D product is formed by stacking a plurality of solidifiedlayers. This embodiment of the apparatus of this disclosure may beapplied to selective laser sintering (SLS), selective laser melting(SLM), direct metal laser sintering (DMLS), or electron beam melting(EBM).

Referring now to FIG. 9, a schematic view of an embodiment of themagnetism unit 20 of this disclosure is schematically shown. Accordingto the disclosure, the magnetism unit for the apparatus for adjustingand controlling the stacking-up layer manufacturing may generate analternative magnetic field, a pulse magnetic field, or a static magneticfield. The magnetism unit 20 may comprise at least one electromagneticmodule 200, a cooling module 201, a switch module 202, and a powersupply module 203.

The electromagnetic module 200, may be coupled with the cooling module201, and may be structured by an electromagnetic member having twomagnetic poles, or at least one simple electromagnetic member.

The cooling module 201 for cooling the electromagnetic module 200 thatgenerates the magnetic field 204 may be selected from a group consistingof an air-cooling apparatus, an atmosphere cooling apparatus, a watercooling apparatus, a medium cooling apparatus, a thermoelectric coolingmodule, a metal heat-dissipating apparatus, a heat-dissipating finapparatus, a honeycomb heat sink apparatus, and any the like.

The switch module 202, may be coupled with the electromagnetic module200, may switch the electromagnetic module 200 around an alternativemode, a pulse mode, and a DC static mode so as to generate analternative magnetic field, a pulse magnetic field, and a staticmagnetic field, respectively.

The power supply module 203, may be coupled with the electromagneticmodule 200, may provide a voltage and a current to control the strengthof the magnetic field 204 of the electromagnetic module 200.

Referring now to FIG. 10, a schematic view of another embodiment of themagnetism unit 30 of this disclosure is shown. In this embodiment, themagnetism unit 30 for generating the alternative magnetic field, thepulse magnetic field or the static magnetic field may be located on topof the target 33. The magnetism unit 30 comprises two electromagneticmodules 31, located oppositely to each other in a symmetric way. Asthese two electromagnetic modules 31 may be energized, a magnetic field32 may be formed in between.

Referring now to FIG. 11, a schematic view of a further embodiment ofthe magnetism unit 40 of this disclosure is shown. In this embodiment,the magnetism unit 40 for generating the alternative magnetic field, thepulse magnetic field or the static magnetic field is located on top ofthe target 44. The magnetism unit 40 may comprise an electromagneticmodule 41, and two electromagnetic poles 42 located under theelectromagnetic module 41 in a symmetric opposing manner. As theelectromagnetic module 41 may be energized, a magnetic field 43 may beformed between the two electromagnetic poles 42.

Referring now to FIG. 12, a schematic view of one more embodiment of themagnetism unit 50 of this disclosure is shown. In this embodiment, themagnetism unit 50 for generating the alternative magnetic field, thepulse magnetic field or the static magnetic field comprises two separateelectromagnetic modules 51, each of which may be structured as asemi-circle to form a half of the circle. As the electromagnetic modules51 is energized, a magnetic field 52 may be formed in the circle, namelybetween the two electromagnetic modules 51. In this embodiment, theelectromagnetic module 51 may be treated as a magnetic pole, so that theinduced magnetic field 52 is formed between these two pairing magneticpoles.

In all of the aforesaid embodiments of the magnetism units, theelectromagnetic module may be embodied as, but not limited to, anelectromagnet.

Referring now to FIG. 13, a flowchart of an embodiment of the method foradjusting and controlling the stacking-up layer manufacturing of thisdisclosure is shown. An apparatus to employ this method for adjustingand controlling the stacking-up layer manufacturing may comprise atarget, a powder providing unit for providing powders onto the target,an energy generating unit for providing an energy beam and a magnetismunit for generating a magnetic field. The method comprises the followingsteps.

S1: Provide a powder onto a surface of the target thereon, in which thetarget may be selected from a group consisting of a plate, a platform,and a semi-finished product, and the powder may be selected from a groupconsisting of selected from a group consisting of a metal, an alloy, ametal-based composite, a polymer, a ceramic, a non-ferrous material, andany material formed by at least two of the foregoing materials

In the first embodiment of the apparatus shown in FIG. 1, the powderproviding unit 10 may be coupled with the displacement unit, theadjustment module 12, the magnetism unit 13 or the energy generatingunit 14, and may provide the powder 102 to the surface of the target 15.In the embodiment of the method, the powder providing unit 10 mayprovide the powder to the surface of the target 15 by a method selectedfrom a group consisting of spraying, depositing, rolling, leveling,laying, and a combination of at least two of the foregoing.

In the second embodiment of the apparatus shown in FIG. 6, the powderproviding unit 10A may provide the powder 102A by laying to the surfaceof the target 15.

In the third embodiment of the apparatus shown in FIG. 7, the powderproviding unit 10B, may be coupled with the energy generating unit 14B,and may provide the powder 102B by spraying to the surface of the target15.

In the fourth embodiment of the apparatus shown in FIG. 8, the powderproviding unit 61, may be coupled with the displacement unit 62, and mayprovide the powder to the surface of the target 64 via the horizontalreciprocating motion of the powder providing unit 61 with respect to thetarget 64.

In the aforesaid embodiments of the targets 15, 64, according tospecific demands, the energy generating unit 13 and the powder providingunit 10, 10A, 10B, 61 may be moved in a correlated manner or in anindependent manner.

S2: Direct an energy beam onto the powder on the surface of the targetso as to melt or sinter a particular area of the powder, and may form amelted or sintered powder layer.

In the first embodiment of the apparatus shown in FIG. 1, while theenergy generating unit 14 provides the energy beam 140 to the powder102, the energy beam 140 may selectively heat the powder so as to have aparticular area to form a melted or sintered powder layer. The methodfor the aforesaid melting or sintering may be selected from a groupconsisting of selective laser sintering (SLS), selective laser melting(SLM), direct metal laser sintering (DMLS), and electron beam melting(EBM).

In the second embodiment of the apparatus shown in FIG. 6, while theenergy generating unit 14 provides the energy beam 140 to the powder102A, the energy beam 140 may selectively heat the powder in aparticular area to form a melted or sintered powder layer.

In the third embodiment of the apparatus shown in FIG. 7, while theenergy generating unit 14B provides the energy beam 140B to the powderon the surface of the target, the energy beam 140 may selectively heatthe powder in a particular area to form a melted or sintered powderlayer.

In the fourth embodiment of the apparatus shown in FIG. 8, though thelocation of the energy generating unit is not shown, yet it may beunderstood that the energy beam may penetrate the spacing in themagnetism unit 63 so as to selectively melt or sinter the powder on theplatform 64.

S3: Provide a magnetic field to the melted or sintered powder layer, andthereby able to control the solidification of the melted or sinteredpowder layer.

In the first embodiment of the apparatus shown in FIG. 1, the magnetismunit 13 may provide the magnetic field 132 to the melted or sinteredpowder layer, so that the material microstructure may be controlledduring the solidification of the melted or sintered powder layer.

In the second embodiment of the apparatus shown in FIG. 6, the magnetismunit 13 may provide a magnetic field 132 to the melted or sinteredpowder layer 102A, so that material microstructure may be controlledduring the solidification of the melted or sintered powder layer.

In the third embodiment of the apparatus shown in FIG. 7, the magnetismunit 13 may provide a magnetic field 132 to the melted or sinteredpowder layer. In his embodiment, the powder providing unit 10B is aspray material providing module located in the energy generating unit14B. As the energy generating unit 14B heats the powder, the powderproviding unit 10B keeps providing the powder 102B onto the surface ofthe target 15.

In the fourth embodiment of the apparatus shown in FIG. 8, the magnetismunit 63 may provide a magnetic field to the melted or sintered powderlayer over the surface of the target 64.

In this disclosure, the aforesaid Steps S2 and S3 may be executedsynchronously, or may be performed in order.

S4: The melted or sintered powder layer is thus solidified into asolidified layer. Then, go back to perform Steps S1 through S3.According to the predetermined 3D sliced layers, the method keepsrepeatedly performing Steps S1 through S3, till a plurality of thesolidified layers may be accumulated or laminated to form the desired 3Dproduct.

In the first, second and fourth embodiments of the apparatus shownrespectively in FIG. 1, FIG. 6 and FIG. 8, the method for the aforesaidmelting or sintering may be selected from a group consisting ofselective laser sintering (SLS), selective laser melting (SLM), Directmetal laser sintering (DMLS), and electron beam melting (EBM).

In the third embodiment of the apparatus shown in FIG. 7, the aforesaidmanufacturing process for forming the melted or sintered powder layermay be a process of laser engineering net shaping (LENS), laser metaldeposition (LMD), or 3D laser cladding.

In summary, this disclosure introduces the technique of controlling thecrystal size by varying or controlling the magnetic field, such that themagnetic field applied upon the melted or sintered powder layer may becontrolled to form satisfied microstructures in the solidified layers aswell as in the 3D product.

In this disclosure, the magnetic field may be an alternative magneticfield, a pulse magnetic field, or a static magnetic field, and astrength of the magnetic field is approximately ranged from 0.001 Tesla(T) to 3,000 T. Following equations demonstrate, typically but notlimited to, a possible physical mechanism of the solidification underthe alternative magnetic field or the pulse magnetic field.P=B _(o) JL sin(ωt)  (Equation 1)P _(v) =P _(vo) +kd ^(−1/2)  (Equation 2)

in which P is the pressure of the electromagnetic vibrator, ω is thealternative frequency, B_(o) is the strength of the magnetic field, J isthe induced current, and d is the crystal size.

Obviously, under the influence of the alternative magnetic field or thepulse magnetic field, the pressure of the electromagnetic vibrator, themagnetic field, the induced current, and the alternative frequency areall correlated. In particular, as the strength of the magnetic field andthe alternative frequency increase, the pressure of the electromagneticvibrator is increased as well.

Refer now to FIG. 14 and FIG. 15, in which Curve A demonstrates atypical Joule heating effect, Curve B demonstrates the correspondingelectromagnetic vibration, and Curve C is the sum of Curve A and CurveB.

Under the efforts of the electromagnetic vibration and the Joule heatingeffect under the alternative magnetic field or the pulse magnetic field,as the magnetic field is initiated, the effect of the electromagneticvibration upon the magnetic field is significant. The grain growth maybe restricted and form a fine grain or amorphous microstructure as thestrength of magnetic field increase. However, as the magnetic field istoo strong, the Joule heating effect may prolong the required coolingtime during the solidification, such that the crystal size may increaseand form a coarse grain. The effects of the microstructure variation maybe dependent to the material properties. Thus, the apparatus forcontrolling the magnetic field in this disclosure may control thesolidification of melted or sintered layers to vary the final microstructure.

Following equations demonstrate, typically but not limited to, apossible physical mechanism of the solidification under the staticmagnetic field.

$\begin{matrix}{v_{I} = {aJ}^{2}} & \left( {{Equation}\mspace{14mu} 3} \right) \\{a = \frac{\rho_{L}\beta\;{g\left( {2R} \right)}^{4}}{144\mu_{v}\lambda_{L}k_{e}^{L}}} & \left( {{Equation}\mspace{14mu} 4} \right)\end{matrix}$

in which ρ_(L) is the density of the liquid-phase metal, β is theexpansion coefficient, g is gravity acceleration, R is the radius of themelted body, μ_(v) is the viscosity coefficient, λ_(L) is theheat-transfer coefficient, and v_(I) is the velocity of the liquid-phasemetal.

Apparently, as velocity of the liquid-phase metal driven by the staticelectromagnetic field is larger than the shifting speed of thesolid-liquid interface during the solidification, the crystallizationorientation may be affected and driven by the static electromagneticfield. At this time, the instant shifting speed of the solid-liquidinterface in the liquid-phase metal is called the critical speed. In thecase that the shifting speed of the solid-liquid interface driven by thestatic electromagnetic field is larger than the critical speed, thecrystallization direction of the microstructure of the material in thestacking-up layer manufacturing would be driven by the magnetic field.

By providing the apparatus and the method for adjusting and controllingthe stacking-up layer manufacturing in accordance with the foregoingdisclosure, the product with complicated shape and controllablecrystallization orientation by conventional techniques in the art maythen be produced.

With respect to the above description then, it is to be realized thatthe optimum factors relationships for the parts of the disclosure, tocomprise variations in size, materials, shape, form, function and mannerof operation, assembly and use, are deemed readily apparent and obviousto one skilled in the art, and all equivalent relationships to thoseillustrated in the drawings and described in the specification areintended to be encompassed by the present disclosure.

What is claimed is:
 1. A method for adjusting and controlling thestacking-up layer manufacturing, comprising the steps of: (a) providinga powder onto a surface of a target; (b) directing an energy beam ontothe powder on the surface of the target to form a melted or sinteredpowder layer; (c) applying a magnetic field to the melted or sinteredpowder layer so as to control a solidification process of the melted orsintered powder layer, and further to form a solidified layer, wherein amaterial microstructure of the solidified layer is varied viacontrolling the solidification process, wherein step (c) furthercomprises the steps of: providing an adjustment module, coupled with amagnetism unit and a displacement unit, wherein the magnetism unit isdisposed within the adjustment module, wherein the adjustment module isdisposed within the displacement unit; wherein the adjustment modulefurther comprises: a turning module, coupled to the displacement unit; aprotrusion module, coupled to the turning module; an angular adjustmentmodule, coupled to the protrusion module; and a tilt module, coupled tothe angular adjustment module, wherein the magnetism unit is coupledwith the tilt module and further comprises a first magnetic pair havingtwo electromagnetic poles, wherein the magnetism unit applies themagnetic field; rotating the magnetism unit around an Z axis by theturning module; adjusting a distance between the two electromagneticpoles of the first magnetic pair by the protrusion module; adjusting anangle of the two electromagnetic poles of the first magnetic pair withrespect to a Y axis by the angular adjustment module; adjusting anelevation angle of the two electromagnetic poles of the first magneticpair with respect to the Z axis by the tilt module; and (d) performingrepeatedly the steps (a), (b), and (c) till a 3D product is formed by asequence stacking with the solidified layers.
 2. The method foradjusting and controlling the stacking-up layer manufacturing of claim1, wherein a mode, a direction, and a strength of the magnetic field areadjustable so as to control the material microstructure of thesolidified layer.
 3. The method for adjusting and controlling thestacking-up layer manufacturing of claim 1, wherein the stacking-uplayer manufacturing is selected from a group consisting of selectivelaser sintering (SLS), selective laser melting (SLM), electron beammelting (EBM), direct metal laser sintering (DMLS), and a method belongto any powder bed fusion additive manufacturing process.
 4. The methodfor adjusting and controlling the stacking-up layer manufacturing ofclaim 1, wherein the method is selected from a group consisting of laserengineering net shaping (LENS), 3D laser cladding, laser metaldeposition (LMD), and a method belong to any direct energy depositionadditive manufacturing process.
 5. The method for adjusting andcontrolling the stacking-up layer manufacturing of claim 1, wherein amaterial of the powder is selected from a group consisting of a metal,an alloy, a metal-based composite, a polymer, a polymer-based composite,a ceramic, a ceramic-based composite, and a combination thereof.
 6. Themethod for adjusting and controlling the stacking-up layer manufacturingof claim 1, wherein the energy beam is selected from a group consistingof a laser beam, an electron beam, an electric arc, and a combinationthereof.
 7. The method for adjusting and controlling the stacking-uplayer manufacturing of claim 1, wherein the powder is coated onto thesurface of the target by a method selected from a group consisting ofspraying, depositing, rolling, leveling, laying, and a combinationthereof.
 8. The method for adjusting and controlling the stacking-uplayer manufacturing of claim 1, wherein a strength of the magnetic fieldis approximately ranged from 0.001 Tesla (T) to 3,000 T.
 9. A controlmethod for an apparatus for adjusting and controlling the stacking-uplayer manufacturing, the apparatus comprising a target, a powderproviding unit for providing a powder onto the target, an energygenerating unit for providing an energy beam and a magnetism unit forgenerating a magnetic field, the control method comprising the steps of:(a) providing the powder onto a surface of the target; (b) directing theenergy beam onto the powder on the surface of the target to form amelted or sintered powder layer; (c) applying the magnetic field to themelted or sintered powder layer so as to control a solidificationprocess of the melted or sintered powder layer and further to form asolidified layer, wherein a material microstructure of the solidifiedlayer is varied via controlling the solidification process, wherein step(c) further comprises the steps of: providing an adjustment module,coupled with a magnetism unit and a displacement unit, wherein themagnetism unit is disposed within the adjustment module, wherein theadjustment module is disposed within the displacement unit; wherein theadjustment module further comprises: a turning module, coupled to thedisplacement unit; a protrusion module, coupled to the turning module;an angular adjustment module, coupled to the protrusion module; and atilt module, coupled to the angular adjustment module, wherein themagnetism unit is coupled with the tilt module and further comprises afirst magnetic pair having two electromagnetic poles, wherein themagnetism unit applies the magnetic field; rotating the magnetism unitaround an Z axis by the turning module; adjusting a distance between thetwo electromagnetic poles of the first magnetic pair by the protrusionmodule; adjusting an angle of the two electromagnetic poles of the firstmagnetic pair with respect to a Y axis by the angular adjustment module;adjusting an elevation angle of the two electromagnetic poles of thefirst magnetic pair with respect to the Z axis by the tilt module; and(d) performing repeatedly the steps (a), (b), and (c) till a 3D productis formed by a sequence stacking with the solidified layers.
 10. Thecontrol method for an apparatus for adjusting and controlling thestacking-up layer manufacturing of claim 9, wherein a mode, a direction,and a strength of the magnetic field are adjustable so as to control amaterial microstructure of the solidified layer.
 11. The control methodfor an apparatus for adjusting and controlling the stacking-up layermanufacturing of claim 10, wherein the stacking-up layer manufacturingis selected from a group consisting of selective laser sintering (SLS),selective laser melting (SLM), direct metal laser sintering (DMLS),electron beam melting (EBM), and a method belong to any powder bedfusion additive manufacturing process.
 12. The control method for anapparatus for adjusting and controlling the stacking-up layermanufacturing of claim 10, wherein the method is selected from a groupconsisting of laser engineering net shaping (LENS), 3D laser cladding,laser metal deposition (LMD), and a method belong to any direct energydeposition additive manufacturing process.
 13. The control method for anapparatus for adjusting and controlling the stacking-up layermanufacturing of claim 10, wherein a material of the powder is selectedfrom a group consisting of a metal, an alloy, a metal-based composite, apolymer, a polymer-based composite, a ceramic, a ceramic-basedcomposite, and a combination thereof.
 14. The control method for anapparatus for adjusting and controlling the stacking-up layermanufacturing of claim 10, wherein the energy beam is selected from agroup consisting of a laser beam, an electron beam, an electric arc, anda combination thereof.
 15. The control method for an apparatus foradjusting and controlling the stacking-up layer manufacturing of claim10, wherein a strength of the magnetic field is approximately rangedfrom 0.001 Tesla (T) to 3,000 T.